Annular sealing system and integrated managed pressure drilling riser joint
An integrated managed pressure drilling (“MPD”) riser joint includes an annular sealing system that allows for the installation, engagement, service, maintenance, disengagement, removal, or replacement of one or more sealing elements while maintaining a pressure tight seal on the annulus without a drill string isolation tool, or equivalent thereof. The integrated MPD riser joint is limited to the annular sealing system and a flow spool, or equivalent thereof, disposed directly below the annular sealing system, without any intervening pressure containment devices or systems. Advantageously, the integrated MPD riser joint does not require a drill string isolation tool, or equivalent thereof, and may be substantially shorter in length and weigh substantially less than a conventional integrated MPD riser joint. The reduction in size and weight enables adoption of MPD technology in applications where conventional integrated MPD riser joints are not economically feasible or are otherwise precluded from use.
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This application is a continuation of PCT International Application PCT/US2019/051234, filed on Sep. 16, 2019, which claims the benefit of, or priority to, U.S. Provisional Patent Application Ser. No. 62/748,232, filed on Oct. 19, 2018, both of which are hereby incorporated by reference in their entirety for all purposes.
BACKGROUND OF THE INVENTIONConventional closed-loop hydraulic drilling systems, sometimes referred to in the industry as managed pressure drilling (“MPD”) systems, include an annular sealing system, a drill string isolation tool, and a flow spool, or equivalents thereof, that actively manage wellbore pressure during drilling and other operations. The annular sealing system typically includes an active control device (“ACD”), a rotating control device (“RCD”), or other type of sealing element that seal the annulus surrounding the drill string or drill pipe such that the annulus is encapsulated and not atmospheric. While the type and kind of annular sealing system may vary based on an application or design, the annular sealing system is designed to maintain a pressure tight seal on the annulus while the drill string or drill pipe is rotated.
The drill string isolation tool is disposed directly below the annular sealing system and typically includes an additional sealing element that is used to encapsulate the well and maintain annular pressure while the annular sealing system, or components thereof, are being installed, serviced, removed, or otherwise disengaged. The flow spool is disposed directly below the drill string isolation tool and, as part of the pressurized fluid return system, diverts fluids from below the annular seal to the surface. The flow spool is in fluid communication with a choke manifold, typically disposed on a platform of the drilling rig, that is in fluid communication with a mud-gas separator or other fluids processing system disposed on a platform of the drilling rig. The pressure tight seal on the annulus allows for the precise control of wellbore pressure by manipulation of the choke settings of the choke manifold and the corresponding application of surface backpressure.
MPD systems find application in both onshore and offshore applications, including, but not limited to, underbalanced drilling (“UBD”), pressurized mud cap drilling (“PMCD”), floating mud cap drilling (“FMCD”), applied surface backpressure (“ASBP”)-MPD, and other MPD drilling applications. However, MPD systems are increasingly becoming necessary, and in some cases, even required, in deepwater and ultra-deepwater applications. In these applications, the annular sealing system, drill string isolation tool, and flow spool are typically configured as part of an integrated MPD riser joint that is installed as part of the upper marine riser system. The integrated MPD riser joint may exceed 50 feet in length and weigh more than 100,000 pounds. In offshore applications, where deck space, weight-carrying capacity, and work space of the floating vessel are substantially constrained, the delivery, installation, and operation of the integrated MPD riser joint may not be feasible.
BRIEF SUMMARY OF THE INVENTIONAccording to one aspect of one or more embodiments of the present invention, a method of maintaining a pressure tight seal on an annulus surrounding drill pipe includes disposing a controllable upper sealing element and a controllable lower sealing element within an annular sealing system, receiving drill pipe through an inner diameter of the upper sealing element and the lower sealing element, controllably sealing the annulus with one or more of the upper sealing element and the lower sealing element, and maintaining the pressure tight seal on the annulus with the annular sealing system while installing, servicing, or removing one or more of the sealing elements of the annular sealing system.
According to one aspect of one or more embodiments of the present invention, an annular sealing system includes a controllable upper sealing element, and a controllable lower sealing element, wherein the upper sealing element and lower sealing element receive drill pipe through an inner diameter, and wherein an annulus surrounding the drill pipe is controllably sealed with one or more of the upper sealing element and the lower sealing element. The annular sealing system maintains a pressure tight seal on the annulus while installing, servicing, or removing one or more of the sealing elements of the annular sealing system.
According to one aspect of one or more embodiments of the present invention, an integrated managed pressure drilling riser joint for maintaining a pressure tight seal on an annulus surrounding drill pipe includes an annular sealing system having a controllable upper sealing element, and a controllable lower sealing element, wherein the upper sealing element and lower sealing element receive drill pipe through an inner diameter, and wherein an annulus surrounding the drill pipe is controllably sealed with one or more of the upper sealing element and the lower sealing element. The integrated managed pressure drilling riser joint includes a flow spool disposed directly below the annular sealing system to divert returning fluids to the surface. The annular sealing system maintains a pressure tight seal on the annulus while installing, servicing, or removing one or more of the sealing elements of the annular sealing system.
Other aspects of the present invention will be apparent from the following description and claims.
One or more embodiments of the present invention are described in detail with reference to the accompanying figures. For consistency, like elements in the various figures are denoted by like reference numerals. In the following detailed description of the present invention, specific details are set forth in order to provide a thorough understanding of the present invention. In other instances, well-known features to one of ordinary skill in the art are purposefully not described to avoid obscuring the description of the present invention.
Despite the benefits provided by MPD technology, there is resistance to its adoption in certain deepwater and ultra-deepwater applications. In some situations, it is not economically feasible due to the cost, complexity, and logistics associated with the delivery and installation of the MPD system offshore. In other situations, it is not possible to deliver and install an MPD system offshore due to constraints on deck space, weight-carrying capacity, and work space of the floating vessel or the conditions of the environment in which it is intended to be used.
Accordingly, in one or more embodiments of the present invention, an integrated MPD riser joint is limited to an annular sealing system and a flow spool, or equivalent thereof, disposed directly below the annular sealing system. Advantageously, the integrated MPD riser joint does not require a drill string isolation tool, or equivalent thereof, and may be substantially shorter in length and weigh substantially less than a conventional integrated MPD riser joint. The reduction in size and weight enables adoption of MPD technology in applications where conventional integrated MPD riser joints are not economically feasible or are otherwise precluded from use. The annular sealing system allows for the installation, engagement, service, maintenance, disengagement, removal, or replacement of one or more sealing elements while maintaining a pressure tight seal on the annulus without a drill string isolation tool, or equivalent thereof. Advantageously, one or more sealing elements may be changed out during hole sections and in between bit runs. During bit runs, the subsea blow out preventer (“SSBOP”) is typically closed allowing the marine riser to be depressurized, such that the annular sealing system may be disengaged, and the sealing elements freely replaced. Notwithstanding, the annular sealing system is capable of maintaining the pressure tight seal on the annulus during bit runs as well, if so desired.
Conventional integrated MPD riser joint 100 includes an annular sealing system 110 disposed below a bottom distal end of the telescopic joint (not shown), a drill string isolation tool 120, or equivalent thereof, disposed directly below annular sealing system 110, and a flow spool 130, or equivalent thereof, disposed directly below drill string isolation tool 120. Annular sealing system 110 may be an ACD-type, RCD-type (not shown), or other type or kind of sealing system (not shown) that seals the annulus (not shown) surrounding the drill string or drill pipe (not shown) such that the annulus is encapsulated and not exposed to the atmosphere. In the ACD-type embodiment depicted, annular sealing system 110 includes an upper sealing element 140 (not shown, reference numeral depicting general location only) and a lower sealing element 150 (not shown, reference numeral depicting general location only) that seals the annulus surrounding the drill string or drill pipe (not shown). Upper sealing element 140 and lower sealing element 150 are typically attached to opposing ends of a mandrel, collectively referred to as a dual seal sleeve, and are engaged or disengaged at the same time. The redundant sealing mechanism extends the life of the sealing elements and increases the safety of operations.
Drill string isolation tool 120, or equivalent thereof, is disposed directly below annular sealing system 110 and provides an additional sealing element 160 (not shown, reference numeral depicting general location only) that encapsulates the well and seals the annulus surrounding the drill string or drill pipe when annular sealing system 110, or components thereof, are being installed, serviced, maintained, removed, or otherwise disengaged. For example, when sealing elements 140 and 150 require replacement while the marine riser is pressurized, such as, for example, during hole sections in between bit runs, drill string isolation tool 120 is engaged to maintain annular pressure while annular sealing system 110 is taken offline. To ensure the safety of operations, sealing element 160 seals the annulus surrounding the drill pipe (not shown) while the sealing elements 140 and 150 of annular sealing system 110 are removed and replaced. Flow spool 130, or equivalents thereof, is disposed directly below drill string isolation tool 120 and, as part of the pressurized fluid return system, diverts fluids (not shown) from below the annular seal to the surface (not shown). Flow spool 130 is in fluid communication with a choke manifold (not shown), typically disposed on a platform of the floating rig (not shown), that is in fluid communication with a mud-gas separator or other fluids processing system (not shown) disposed on the surface.
The pressure tight seal on the annulus provided by annular sealing system 110 allows for the precise control of wellbore pressure by manipulation of the choke settings of the choke manifold (not shown) and the corresponding application of surface backpressure. If the driller wishes to increase wellbore pressure, one or more chokes of the choke manifold (not shown) may be closed somewhat more than their last setting to further restrict fluid flow and apply additional surface backpressure. Similarly, if the driller wishes to decrease wellbore pressure, one or more chokes of the choke manifold (not shown) may be opened somewhat more than their last setting to increase fluid flow and reduce the amount of surface backpressure applied.
While not shown, one of ordinary skill in the art will recognize that RCD-type annular sealing systems (not shown) typically include an upper sealing element (not shown) and a lower sealing element (not shown) that seal the annulus surrounding drill pipe 240, however, the dual sealing elements (not shown) rotate with drill pipe 240 while maintaining the pressure tight seal. Like ACD-type annular sealing systems (e.g., 110 of
In the disclosure that follows, one or more embodiments of the present invention are described relating to an integrated MPD riser joint consisting of an annular sealing system and a flow spool, or equivalent thereof, and specifically excludes a drill string isolation tool, or equivalent thereof. The annular sealing system maintains the pressure tight seal on the annulus while installing, servicing, or removing one or more of the sealing elements of the annular sealing system without any intervening pressure containment device or system.
In one or more embodiments of the present invention, a method of maintaining a pressure tight seal on an annulus surrounding drill pipe may include disposing an independently controllable upper sealing element and an independently controllable lower sealing element within an annular sealing system, receiving drill pipe through an inner diameter of the upper sealing element and the lower sealing element, controllably sealing the annulus with one or more of the upper sealing element and the lower sealing element, and maintaining a pressure tight seal on the annulus with the annular sealing system while installing, servicing, or removing one or more sealing elements of the annular sealing system. In certain embodiments, one or more of the sealing elements of the annular sealing system may maintain the pressure tight seal on the annulus. In other embodiments, one or more annular packers of the annular sealing system may maintain the pressure tight seal on the annulus. In still other embodiments, a combination of one or more sealing elements and one or more annular packers of the annular sealing system may maintain the pressure tight seal on the annulus.
In one or more embodiments of the present invention, an integrated MPD riser joint may include an annular sealing system having an independently controllable upper sealing element and an independently controllable lower sealing element. The upper sealing element and the lower sealing element may receive drill pipe through their inner diameter and the annulus surrounding the drill pipe may be controllably sealed with one or more of the upper sealing element and the lower sealing element. In certain embodiments, the annular sealing system may be an ACD-type annular sealing system. In other embodiments, the annular sealing system may be an RCD-type annular sealing system. In still other embodiments, the annular sealing system be a hybrid or any other type or kind of annular sealing system. A flow spool, or equivalent thereof, may be disposed directly below the annular sealing system, without any intervening pressure containment device or system, and may divert returning fluids to the surface. The annular sealing system may maintain the pressure tight seal on the annulus while installing, servicing, or removing one or more of the sealing elements and without any other pressure containment device or system. In certain embodiments, one or more of the sealing elements of the annular sealing system may maintain the pressure tight seal on the annulus. In other embodiments, one or more annular packers of the annular sealing system may maintain the pressure tight seal on the annulus. In still other embodiments, a combination of one or more sealing elements and one or more annular packers of the annular sealing system may maintain the pressure tight seal on the annulus.
In certain embodiments, the upper sealing element and the lower sealing element may be discrete components independently controllable and moveable. In such embodiments, one sealing element may be installed, engaged, serviced, disengaged, or removed while the other sealing element or an annular packer of the annular sealing system maintains the pressure tight seal on the annulus. In other embodiments, the upper sealing element and the lower sealing element may be attached to opposing ends of a spring-biased mandrel, the sealing elements may be independently controllable, and the sealing element disposed on the spring-biased end of the mandrel may be independently moveable from the other sealing element. In such embodiments, one sealing element may be installed, engaged, serviced, disengaged, or removed while the other sealing element or an annular packer of the annular sealing system maintains the pressure tight seal on the annulus. In still other embodiments, the upper sealing element and the lower sealing element may be attached to opposing ends of a spacer mandrel and the sealing elements may be independently controllable. A dual seal sleeve may include the upper sealing element, the spacer mandrel, and a lower sealing element. In such embodiments, one or more sealing elements or one or more annular packers may maintain the pressure tight seal on the annulus.
One of ordinary skill in the art will recognize that the above-noted embodiments are merely exemplary and other configurations that provide for the independent control of the sealing elements of the annular sealing system and, in some embodiments, one or more annular packer systems, that are capable of maintaining annular pressure while one or more of the sealing elements are being installed, engaged, serviced, disengaged, or removed, without the use of a drill string isolation tool, or equivalent thereof, is within the scope of one or more embodiments of the present invention.
Advantageously, the annular sealing system may be disposed directly above a flow spool, or equivalent thereof, without any intervening pressure containment device or system required as part of the integrated MPD riser joint. Because the integrated MPD riser joint may be limited to just the annular sealing system and the flow spool, or the equivalent thereof, the height and weight of the integrated MPD riser joint may be substantially reduced and logistic feasibility of delivery and installation may be substantially improved.
In contrast, annular sealing system 400 may include one or more pluralities of locking dogs 410 (not shown, reference numeral depicting general location only) disposed above the top side of upper annular packer 200a and one or more pluralities of locking dogs 415 (not shown, reference numeral depicting general location only) disposed below the bottom side of upper annular packer 200a that span the area where an independently controllable upper sealing element (not shown) may be operatively disposed and one or more pluralities of locking dogs 425 (not shown, reference numeral depicting general location only) disposed above the top side of lower annular packer system 200b and one or more pluralities of locking dogs 420 (not shown, reference numeral depicting general location only) disposed below the bottom side of lower annular packer system 200b that span the area where an independently controllable lower sealing element (not shown) may be operatively disposed.
To assist in guiding the retrieval and deployment of sealing elements (not shown), one or more proximity sensors may be disposed in annular sealing system 400. In certain embodiments, annular sealing system 400 may include one or more proximity sensors 430 (not shown, reference numeral depicting general location only) disposed above the top side of upper annular packer system 200a and one or more proximity sensors 435a (not shown, reference numeral depicting general location only) disposed below the bottom side of upper annular packer system 200a that bookend the area where the upper sealing element (not shown) may be operatively disposed and one or more proximity sensors 435b (not shown, reference numeral depicting general location only) disposed above the top side of lower annular packer system 200b and one or more proximity sensors 440 (not shown, reference numeral depicting general location only) disposed below the bottom side of lower annular packer system 200b that bookend the area where the lower sealing element (not shown) may be operatively disposed. The proximity sensors may be of any type or kind suitable for detecting the proximate location of the sealing elements (not shown) within annular sealing system 400. One of ordinary skill in the art will recognize that the type or kind, number, and location of proximity sensors disposed within annular sealing system 400 may vary based on application or design in accordance with one or more embodiments of the present invention.
During operations involving running one or more sealing elements (not shown) in or out, the risk of dropping a sealing element (not shown) onto one or more of the pluralities of locking dogs (e.g., 415, 420, and 425) may be mitigated by monitoring one or more proximity sensors (e.g., 430, 435, 440). In addition, the risk of dropping a sealing element (not shown) downhole is eliminated by the pluralities of locking dogs (e.g., 415, 420, and 425) extended in the locked state and an optional no-go shoulder (not shown) disposed within annular sealing system 400 below lower annular packer system 200b. The no-go-shoulder (not shown) may prevent a sealing element (not shown) from falling through and escaping annular sealing system 400.
One of ordinary skill in the art will recognize that an RCD-type annular sealing system (not shown) may include a similar plurality of locking dogs (not shown) and proximity sensors (not shown) to secure and detect seal and bearing assemblies (not shown) in a similar manner as described herein with respect to an ACD-type annular system 400 in accordance with one or more embodiments of the present invention.
Each sealing element 230a, 230b may be substantially cylindrical in shape and have an inner diameter may receive drill pipe (not shown) therethrough with a close fit. During drilling operations, one or more of upper sealing element 230a and lower sealing element 230b may be engaged to provide an interference fit that seals the annulus (not shown) surrounding the drill pipe (not shown). Conventional ACD-type annular sealing systems (not shown) use a dual seal sleeve configuration including two sealing elements (not shown) disposed on opposing ends of a single mandrel (not shown) that are engaged at the same time to provide redundant sealing and increase the safety of operations. In contrast, in one or more embodiments of the present invention, upper sealing element 230a and lower sealing element 230b may be independently engaged or disengaged and independently moved in between bit runs while the annular sealing system (e.g., 400 of
In operation, an independently controllable upper sealing element 230a may be disposed on a first spacer mandrel 510 and an independently controllable lower sealing element 230b may be disposed on a second spacer mandrel 520 within the annular sealing system (e.g., 400 of
In typical applications, upper sealing element 230a and lower sealing element 230b are engaged at the same time to provide a redundant seal. For reasons beyond the scope of this disclosure, one of sealing elements 230a or 230b may wear at a faster rate than the other (typically, the upper sealing element 230a). If one of sealing elements 230a or 230b wears out in between bit runs, the worn sealing element 230a or 230b must be replaced, causing a premature end to drilling activities, substantial non-productive downtime, and requiring the time-consuming, complex, and costly task of depressurizing the marine riser (not shown). As such, it is highly desirable to be able to replace the worn sealing element 230a and/or 230b without depressurizing the marine riser (not shown), thereby minimizing non-productive downtime and safely maintaining marine riser (not shown) pressure. In one or more embodiments of the present invention, when a decision has been taken to replace a worn sealing element 230a or 230b, a stand of drill pipe (not shown) may be stripped out of upper sealing element 230a and lower sealing element 230b.
Continuing,
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One of ordinary skill in the art will recognize that, while the above-noted description described the retrieval of both upper sealing element 230a and lower sealing element 230b during a single run of running tool 530, the operation could easily be modified to retrieve only upper sealing element 230a in a similar manner to that described above. For example, upper annular packer system 200a may be disengaged such that upper sealing element 230a unseals the annulus surrounding running tool 530. The pressure of intermediate area 405 may be equalized with marine riser pressure above upper annular packer 200a. The plurality of locking dogs 410 (not shown, reference numeral depicting general location only) disposed above the top side of the upper annular packer system 200a may be unlocked. Running tool 530 may then strip out with upper sealing element 230a only. In such an application, lower sealing element 230b may independently maintain the annular seal surrounding running tool 530 while upper sealing element 230a alone is retrieved.
The pressure in the intermediate area may be equalized with wellbore pressure. Lower annular packer system 200b may be disengaged to unseal the annulus surrounding running tool 530. Running tool 530 may strip in to position replacement lower sealing element 230b in place relative to lower annular packer system 200b by setting it down on the plurality of locking dogs 420 (not shown, reference numeral depicting general location only) disposed below lower annular packer system 200b. A plurality of locking dogs 425 (not shown, reference numeral depicting general location only) disposed above the top side of lower annular packer system 200b may be locked. The setting may be tested by pulling up on running tool 530. Continuing,
One of ordinary skill in the art will recognize that, while the above-noted description described the deployment of both upper sealing element 230a and lower sealing element 230b during a single run of running tool 530, the operation could easily be modified to deploy only upper sealing element 230a in a similar manner to that described above. For example, upper annular packer system 200a may be disengaged. The pressure of intermediate area 405 may be equalized with marine riser pressure above upper annular packer 200a. The plurality of locking dogs 410 (not shown, reference numeral depicting general location only) disposed above the top side of the upper annular packer system 200a may be unlocked. Running tool 530 may then strip in with upper sealing element 230a only until upper sealing element 230a comes to rest on the plurality of locking dogs 415 (not shown, reference numeral depicting general location only) disposed below the bottom side of upper packer system 200a. The plurality of locking dogs 410 (not shown, reference numeral depicting general location only) may be locked to secure upper sealing element 230a in place. In such an application, lower sealing element 230b may independently maintain the annular seal surrounding running tool 530 while upper sealing element 230a alone is deployed.
Continuing,
Each sealing element 230a, 230b may be substantially cylindrical in shape and have an inner diameter that may receive drill pipe (not shown) therethrough with a close fit. During drilling operations, one or more of upper sealing element 230a and lower sealing element 230b may be engaged to provide an interference fit that seals the annulus (not shown) surrounding the drill pipe (not shown). Conventional ACD-type annular sealing systems (not shown) use a dual seal sleeve including two sealing elements (not shown) disposed on opposing ends of a single mandrel (not shown) that are engaged at the same time to provide redundant sealing and increase the safety of operations. In contrast, in one or more embodiments of the present invention, upper sealing element 230a and lower sealing element 230b may be independently engaged or disengaged and independently moved in between bit runs while the annular sealing system (e.g., 400 of
In operation, upper sealing element 230a and lower sealing element 230b, disposed on opposing ends of spring-biased mandrel 710, may be disposed within the annular sealing system (e.g., 400 of
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Each sealing element 230a, 230b may be substantially cylindrical in shape and have an inner diameter that may receive drill pipe (not shown) therethrough with a close fit. During drilling operations, one or more of upper sealing element 230a and lower sealing element 230b may be engaged to provide an interference fit that seals the annulus (not shown) surrounding the drill pipe (not shown). Conventional ACD-type annular sealing systems (not shown) use a dual seal sleeve configuration including two sealing elements (not shown) disposed on opposing ends of a single mandrel (not shown) that are engaged at the same time to provide redundant sealing and increase the safety of operations. In contrast, in one or more embodiments of the present invention, upper sealing element 230a and lower sealing element 230b may be independently engaged or disengaged and independently moved in between bit runs while the annular sealing system (e.g., 400 of
In operation, independently controllable upper sealing element 230a and independently controllable lower sealing element 230b may be disposed within the annular sealing system (e.g., 400 of
In typical applications, upper sealing element 230a and lower sealing element 230b are engaged at the same time to provide a redundant seal. For reasons beyond the scope of this disclosure, one of sealing elements 230a or 230b may wear at a faster rate than the other (typically the upper sealing element 230a). If one of sealing elements 230a or 230b wears out in between bit runs, the worn sealing element 230a or 230b must be replaced, causing a premature end to drilling activities, requiring substantial non-productive downtime, and the time-consuming, complex, and costly task of depressurizing the marine riser (not shown). As such, it is highly desirable to be able to replace the worn sealing element 230a or 230b without depressurizing the marine riser (not shown), thereby minimizing non-productive downtime and safely maintaining marine riser (not shown) pressure. In one or more embodiments of the present invention, when a decision has been taken to replace a worn sealing element 230a or 230b, a stand of drill pipe (not shown) may be stripped out of upper sealing element 230a and lower sealing element 230b.
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Advantages of one or more embodiments of the present invention may include, but is not limited to, one or more of the following:
In one or more embodiments of the present invention, an annular sealing system allows for the installation, engagement, service, maintenance, disengagement, removal, or replacement of one or more sealing elements while maintaining a pressure tight seal on the annulus. Advantageously, one or more sealing elements may be changed out during hole sections and in between bit runs. During bit runs, the SSBOP is typically closed allowing the marine riser to be depressurized, such that the annular sealing system may be disengaged, and the sealing elements freely replaced. Notwithstanding, the annular sealing system is capable of maintaining the pressure tight seal on the annulus during bit runs as well, if so desired.
In one or more embodiments of the present invention, an integrated MPD riser joint may be limited to the annular sealing system and a flow spool, or equivalent thereof, disposed directly below the annular sealing system. Advantageously, the integrated MPD riser joint may be substantially shorter in length and weigh substantially less than a conventional integrated MPD riser joint. The reduction in size and weight enables adoption of MPD technology in applications where conventional integrated MPD riser joints are not economically feasible or are otherwise precluded from use for technical reasons.
In one or more embodiments of the present invention, an annular sealing system includes a discrete and independently controllable upper sealing element and a discrete and independently controllable lower sealing element. One of the sealing elements may be installed, engaged, serviced, disengaged, or removed while the other sealing element maintains the pressure tight seal on the annulus.
In one or more embodiments of the present invention, an annular sealing system includes an upper sealing element and a lower sealing element that are attached to a spring-biased mandrel, where the upper sealing element and the lower sealing element are independently controllable. One of the sealing elements may be installed, engaged, serviced, disengaged, or removed while the other sealing element, or one or more annular packers, maintains the pressure tight seal on the annulus.
In one or more embodiments of the present invention, an annular sealing system includes an upper sealing element and a lower sealing element that are attached to a spacer mandrel, where the upper sealing element and the lower sealing element are independently controllable. One of the sealing elements may be installed, engaged, serviced, disengaged, or removed while the other sealing element, or one or more annular packers, maintains the pressure tight seal on the annulus.
In one or more embodiments of the present invention, an annular sealing system may be an active control device that includes an upper annular packer system and a lower annular packer system that may independently engage or disengage the upper sealing element and the lower sealing element (and drill pipe disposed therethrough) or the running tool.
In one or more embodiments of the present invention, an annular sealing system may be a rotating control device where the upper sealing element is disposed within an upper seal and bearing assembly and the lower sealing element is disposed within a lower seal and bearing assembly.
In one or more embodiments of the present invention, an annular sealing system may be substituted for a conventional annular sealing system and drill string isolation tool, or equivalent thereof, as part of an integrated MPD riser joint.
In one or more embodiments of the present invention, an annular sealing system, that does not require the use of a drill string isolation tool, or equivalent thereof, is substantially the same size and weight as a conventional annular sealing system that requires the use of a drill string isolation tool, or equivalent thereof.
In one or more embodiments of the present invention, the costs associated with delivering, installing, operating, and removal an integrated MPD riser joint with an annular system are substantially reduced.
In one or more embodiments of the present invention, an integrated MPD riser joint with an annular sealing system is substantially smaller in size and weighs substantially less than a conventional integrated MPD riser joint due to the removal of the drill string isolation tool, or equivalent thereof. As such, the desk space and weight-carrying capacity required to deliver the integrated MPD riser joint, and associated costs, is substantially less than that of a conventional integrated MPD riser joint. In addition, installation and removal of the integrated MPD riser joint is substantially easier and safer than that of a conventional integrated MPD riser joint.
While the present invention has been described with respect to the above-noted embodiments, those skilled in the art, having the benefit of this disclosure, will recognize that other embodiments may be devised that are within the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the appended claims.
Claims
1. An integrated MPD riser joint for maintaining a pressure tight seal on an annulus surrounding drill pipe comprising:
- an annular sealing system comprising: a controllable upper sealing element, and a controllable lower sealing element, wherein the upper sealing element and lower sealing element receive drill pipe through an inner diameter, and wherein an annulus surrounding the drill pipe is controllably sealed with one or more of the upper sealing element and the lower sealing element; and
- a flow spool disposed directly below the annular sealing system that diverts returning fluids to the surface,
- wherein the upper sealing element and the lower sealing element are attached to a spacer mandrel and are independently controllable, and
- wherein the annular sealing system maintains a pressure tight seal on the annulus while installing, servicing, or removing one or more of the sealing elements of the annular sealing system.
2. The integrated MPD riser joint of claim 1, wherein the annular sealing system maintains the pressure tight seal on the annulus while one or more sealing elements are installed, engaged, serviced, maintained, disengaged, or removed without any other pressure containment device or system.
3. The integrated MPD riser joint of claim 1, wherein the upper sealing element is installed, engaged, serviced, disengaged, or removed while the lower sealing element or an annular packer system of the annular sealing system maintains the pressure tight seal on the annulus.
4. The integrated MPD riser joint of claim 1, wherein the lower sealing element is installed, engaged, serviced, disengaged, or removed while the upper sealing element or an annular packer system of the annular sealing system maintains the pressure tight seal on the annulus.
5. The integrated MPD riser joint of claim 1, wherein the upper sealing element and the lower sealing element are discrete components that are independently moveable and controllable.
6. The integrated MPD riser joint of claim 1, wherein the upper sealing element and the lower sealing element are attached to a spring-biased mandrel and are independently controllable.
7. The integrated MPD riser joint of claim 1, wherein the annular sealing system comprises an upper packer system that engages or disengages the upper sealing element or a running tool and a lower packer system that engages or disengages the lower sealing element or the running tool.
8. The integrated MPD riser joint of claim 1, wherein the upper sealing element is disposed within an upper seal and bearing assembly and the lower sealing element is disposed within a lower seal and bearing assembly.
9. A method of maintaining a pressure tight seal on an annulus while removing or installing a plurality of sealing elements of an annular sealing system comprising:
- disposing a controllable upper sealing element on a first spacer mandrel and a controllable lower sealing element on a second spacer mandrel within an annular sealing system, wherein the upper sealing element is positioned for engagement by an upper packer system and the lower sealing element is positioned for engagement by a lower packer system of the annular sealing system;
- disposing drill pipe through an inner diameter of the annular sealing system;
- engaging the annular sealing system during drilling operations;
- stripping out a stand of drill pipe disposed within the upper sealing element and the lower sealing element of the annular sealing system;
- stripping in with a running tool through the upper sealing element and the lower sealing element;
- engaging the upper packer system to seal the annulus with the upper sealing element;
- disengaging a lower packer system to unseal the annulus with the lower sealing element;
- unlocking a plurality of locking dogs disposed above a top side of the lower packer system;
- pulling the lower sealing element into an intermediate area within the annular sealing system between a plurality of locking dogs disposed below a bottom side of the upper annular packer system and a plurality of locking dogs disposed above a top side of the lower annular packer system;
- locking the plurality of locking dogs disposed above the top side of the lower annular packer system;
- engaging the lower annular packer system to seal the annulus with the lower annular packer;
- disengaging an upper annular packer system to unseal the annulus with the upper sealing element;
- unlocking a plurality of locking dogs disposed above a top side of the upper annular packer system;
- stripping out the running tool until the upper sealing element clears the upper annular packer system;
- unlocking a plurality of locking dogs disposed below the bottom side of the upper annular packer system; and
- stripping out the running tool with the upper sealing element and the lower sealing element.
10. The method of claim 9, further comprising:
- stripping in with the running tool with a replacement upper sealing element and a replacement lower sealing element;
- setting the replacement upper sealing element in place relative to the upper annular packer system;
- locking the plurality of locking dogs disposed below the bottom side of the upper annular packer system;
- locking the plurality of locking dogs disposed above the top side of the upper annular packer system;
- engaging the upper annular packer system to seal the annulus surrounding the running tool with the upper sealing element;
- equalizing the intermediate area with wellbore pressure;
- disengaging the lower annular packer system to unseal the annulus surrounding the running tool;
- setting the replacement lower sealing element in place relative to the lower annular packer system;
- locking the plurality of locking dogs disposed above the top side of the lower annular packer system;
- engaging the lower annular packer system to seal the annulus surrounding the running tool with the lower sealing element;
- stripping out the running tool; and
- stripping in with the stand of drill pipe.
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Type: Grant
Filed: Apr 16, 2021
Date of Patent: May 17, 2022
Patent Publication Number: 20210230963
Assignee: GRANT PRIDECO, INC. (Houston, TX)
Inventors: Austin Johnson (Houston, TX), Justin Fraczek (The Woodlands, TX), Robert H. J. Pinkstone (Chester)
Primary Examiner: Aaron L Lembo
Application Number: 17/233,082
